Window sill flashing

Abstract

The present invention is directed towards a window sill flashing comprising a base having a substantially rectangular shape. A front flange projects perpendicularly downward from a front edge of the base and at least one side flange extends vertically from a side edge of the base. The side flange includes a front surface. The window sill flashing is made from a rigid homopolymer vinyl film.

The invention claimed is: 
     
       1. A window sill flashing, comprising a first one-piece sill flashing and a second one-piece sill flashing that are each a continuous shaped structure and each include:
 (i) a base having a substantially rectangular shape and having a front edge and at least one side edge; 
 (ii) a front flange projecting perpendicularly downward from the front edge of the base; 
 (iii) at least one side flange having a side surface and a front surface, wherein the side surface extends vertically from the at least one side edge of the base and the front surface is coplanar and continuous with the front flange and extends perpendicularly from the side surface; and 
 wherein the first one-piece sill flashing and the second one-piece sill flashing are free of seams; 
 wherein the first one-piece sill flashing and the second one-piece sill flashing are comprised of a polyvinyl chloride; 
 wherein the first one-piece sill flashing and the second one-piece sill flashing each have a thickness in a range of about 7.5 mils to about 35 mils; 
 wherein the first one-piece sill flashing and the second one-piece sill flashing are each free of any metallic flanges and free of any metallic coverings applied to a lower surface of the base and an upper surface of the base opposite the lower surface; 
 wherein the first one-piece sill flashing and the second one-piece sill flashing are configured to partially overlap to produce the window sill flashing having a length generally equal to a width of a window opening; and 
 wherein the lower surface of the base of the first one-piece sill flashing and the lower surface of the base of the second one-piece sill flashing are configured to be in direct contact with a housewrap at a bottom portion of the window opening. 
 
     
     
       2. The window sill flashing of  claim 1 , wherein the first one-piece sill flashing and the second one-piece sill flashing are each a vacuum-formed unitary structure. 
     
     
       3. The window sill flashing of  claim 1 , wherein the first one-piece sill flashing and the second one-piece sill flashing are each free of a rear wall projecting from a rear edge of the base, opposite the front edge. 
     
     
       4. The window sill flashing of  claim 1 , wherein the first one-piece sill flashing and the second one-piece sill flashing each include a rear wall which extends perpendicularly upward along a rear edge of the base, opposite the front edge, and the rear wall is part of the continuous shaped structure. 
     
     
       5. The window sill flashing of  claim 2 , wherein the first one-piece sill flashing and the second one-piece sill flashing consist of a thermoformed film having the polyvinyl chloride. 
     
     
       6. The window sill flashing of  claim 1 , wherein the first one-piece sill flashing and the second one-piece sill flashing consist of the polyvinyl chloride. 
     
     
       7. The window sill flashing of  claim 1 , wherein a silicone coating covers both the first one-piece sill flashing and the second one-piece sill flashing. 
     
     
       8. The window sill flashing of  claim 1 , wherein the first one-piece sill flashing overlaps the second one-piece sill flashing so that the base of the first one-piece sill flashing overlaps the base of the second one-piece sill flashing and the front flange of the first one-piece sill flashing overlaps the front flange of the second one-piece sill flashing. 
     
     
       9. The window sill flashing of  claim 8 , wherein an adhesive tape is located on an overlap between the first one-piece sill flashing and the second one-piece sill flashing to seal a seam between the first one-piece sill flashing and the second one-piece sill flashing. 
     
     
       10. The window sill flashing of  claim 1 , wherein the base of both the first one-piece sill flashing and the second one-piece sill flashing is free of dimples. 
     
     
       11. A method of making and installing a window sill flashing, comprising:
 a) forming a first one-piece sill flashing that is a continuous shaped structure without seams which includes:
 (i) a base having a substantially rectangular shape and a front edge and at least one side edge; 
 (ii) a front flange projecting perpendicularly downward from the front edge of the base; 
 (iii) at least one side flange having a side surface and a front surface, wherein the side surface extends vertically from the at least one side edge of the base and the front surface is coplanar and continuous with the front flange and extends perpendicularly from the side surface; 
 
 b) forming a second one-piece sill flashing that is a continuous shaped structure without seams which includes:
 (i) a base having a substantially rectangular shape and a front edge and at least one side edge; 
 (ii) a front flange projecting perpendicularly downward from the front edge of the base; 
 (iii) at least one side flange having a side surface and a front surface, wherein the side surface extends vertically from the at least one side edge of the base and the front surface is coplanar and continuous with the front flange and extends perpendicularly from the side surface; and 
 
 c) applying a housewrap to a window opening such that the housewrap covers a bottom portion of the window opening and a portion of an exterior wall in which the window opening is located; 
 d) installing the first one-piece sill flashing and the second one-piece sill flashing such that they are located on the bottom portion of the window opening having the housewrap thereon; 
 wherein the first one-piece sill flashing and the second one-piece sill flashing partially overlap and are in direct contact with one another to produce the window sill flashing having a length generally equal to a width of the window opening; 
 wherein the base of both the first one-piece sill flashing and the second one-piece sill flashing is in direct contact with the bottom portion of the window opening having the housewrap thereon; 
 wherein both the first one-piece sill flashing and the second one-piece sill flashing are free of any metallic flanges and free of any metallic coverings applied to a lower surface of the base or an upper surface of the base opposite the lower surface; 
 wherein the forming of the first one-piece still flashing and the second one-piece sill flashing is a vacuum-forming of a thermoforming film; and 
 wherein the first one-piece sill flashing and the second one-piece sill flashing each have a thickness in the range of about 7.5 mils to 35 mils. 
 
     
     
       12. The method of  claim 11 , wherein the first one-piece sill flashing is formed from a first common sheet. 
     
     
       13. The method of  claim 12 , wherein the second one-piece sill flashing is formed from a second common sheet. 
     
     
       14. The method of  claim 11 , wherein the thermoforming film comprises a polyvinyl chloride. 
     
     
       15. The method of  claim 11 , wherein the method includes applying a silicone coating to cover both the first one-piece sill flashing and the second one-piece sill flashing. 
     
     
       16. The method of  claim 11 , wherein after the forming, the first one-piece sill flashing and the second one-piece sill flashing are each free of a rear wall projecting from a rear edge of the base, opposite the front edge. 
     
     
       17. The method of  claim 11 , wherein the first one-piece sill flashing and the second one-piece sill flashing are each formed to also include a rear wall which extends perpendicularly upward along a rear edge of the base, opposite the front edge, and the rear wall is part of the continuous shaped structure.